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Bulk Material Handling

Understanding the Dynamics of Material Flow

The challenges of conveying and processing dry bulk material are often not readily apparent to processors when selecting bulk material equipment. The consideration of factors that are attributed to equipment size and selection focus on;

These are just some of the foundational elements considered when equipment is selected for conveying, feeding, unloading, and filling. Challenges arise when these are the only elements considered when equipment is designed. Processors share in the frustration of dry material systems not meeting production capacity and struggle with material flow issues even though equipment is sized and rated for the specified elements listed above.

Unlike gaseous and liquid systems where in absence of pressure drops, the state of the product conveyed or transported does not fluctuate much. In bulk materials however, this is not always the case. Bulk density as an example is not a constant figure. The same material can have varying bulk densities in different stages of production causing flow rates to change creating the need for processing formulas to be adjusted. There have been numerous studies and articles written to try to explain this dynamic. You can read our white paper Material Effect on Power Requirements for Screw Feeders as reference to this point.

Influence of Feed Material on the Performance of New Plants

Studies also show that start-up systems for material solids typically only hit 40% of stated production rate in the first year. * This is a dramatic figure when considering the wide range of industries which process bulk solids. Food, nutraceutical, pharmaceutical, chemical, building materials, minerals processing, and others are challenged by the shear characteristics of the raw materials of the process.

To overcome these challenges, best practices suggests having material tests performed prior to equipment purchase and experience. Relying on an experienced vendor who has tested, and understands the dynamic nature of bulk materials to guide equipment layout and options to avoid pitfalls in expected output.

The 6 Key Considerations for Selecting the Right Conveyor for Your Process

Selecting a conveyor for a batch or continuous processing application is not always as straightforward as you might think. In fact, it almost never is. Moving material consistently – at a rate that is in line with production requirements and in a manner...Read more.

In bulk material handling processes, there can be a lot of drama associated with the subject of material degradation. That’s because maintaining product integrity from start to finish is the key to material quality and a healthy bottom line...Read more.